Tetra Pak showcases Tetra Lactenso® Aseptic with OneStep technology at Anuga FoodTec 2012

New technology in best-practice line for processing aseptic white milk shortens processing time by up to 90 per cent, cuts operating costs by up to 50 per cent

Tetra Pak showcases Tetra Lactenso Aseptic with OneStep technology, a best-practice line that incorporates UHT white milk production within a single, high-throughput process at Anuga FoodTec.

OneStep technology eliminates the need for pasteurisation pre-treatment and intermediate storage of raw milk. In one unbroken step, raw milk is preheated, clarified, separated, standardised and homogenised before undergoing UHT treatment and regenerative cooling; it is then transferred to two aseptic buffer tanks. This shortens processing time from as much as two days to just a few hours; cutting operating costs by up to 50 per cent compared with conventional solutions.

In essence, the innovation of OneStep technology is that it combines heat treatment, separation and standardisation into a single step, which significantly simplifies and accelerates the production process.

In addition to shortening the time it takes to process raw milk, OneStep technology also incorporates aseptic buffering. This enables completely automated and continuous UHT operations, with fewer process steps and smaller hold-up volumes in the line.

“The whole process is far more efficient than conventional solutions, delivering significant operating cost savings and greatly reducing environmental impact,” said Bengt Eliasson, manager, Tetra Pak Dairy Aseptic Solutions. “Capital costs are also lower because a lot less equipment and floor space are needed when using OneStep.”

Tetra Lactenso Aseptic with OneStep technology can reduce energy consumption by more than 40 per cent, reduce effluent load by up to 40 per cent and cut water consumption by as much as 60 per cent. These savings are estimated to reduce the carbon footprint of the production process by around 40 per cent. Furthermore, the streamlined process cuts product loss by up to 33 per cent compared to conventional UHT solutions.

With the ability to change the fat content of milk products without stopping production – and to run milk with different fat contents at the same time - OneStep technology provides outstanding aseptic line flexibility, enabling efficient production planning and high utilisation of filling machines with up to 100 per cent availability.

Said Eliasson: We’ll be showing a Tetra Lactenso Aseptic with OneStep technology at Anuga FoodTec 2012 and demonstrating how it gives customers a shortcut to UHT milk production, maximising both product quality and safety with hygienic design in every detail and full traceability and control of the line. And like all of our Tetra Lactenso Aseptic best-practice lines for dairy production, our promise is backed by a validated performance guarantee. Tetra Lactenso Aseptic with OneStep technology is a best-practice line that exemplifies how Tetra Pak works with best-practice key units and tools, expertise in food technology, and proven functionalities for lines and plants to solve their customers’ production challenges.

Equipment included in Tetra Lactenso Aseptic with OneStep technology:

Raw milk silo tanks for raw milk reception.

Tetra Therm Aseptic Flex – A UHT unit that integrates UHT heat treatment with separation and standardisation. It is designed to meet each dairy’s specific needs while achieving the lowest utility consumption and highest availability on the market, low product losses and total control for efficient and safe food production.
Tetra Spiraflo – A tubular heat exchanger, with high energy recovery that contributes to cutting energy consumption. It incorporates the unique Floating Protection System, a thermal-stress-absorbing design that enhances food safety and enables increased efficiency.
Tetra Centri AirTight Eco –The world’s first and only hermetic direct-driven separator. It delivers separation efficiency, high product quality, and greater production flexibility. It also cuts costs and environmental impact by reducing energy consumption by up to 35 per cent.
Tetra Alfast – An integrated unit for standardisation of milk and cream, thanks to the SpotOn function that prevents fat content deviation in the final product with continuous control of milk fat content in the aseptic tank.
Tetra Alex – A homogeniser, with high efficiency, that enables you to cut your electricity costs. The pioneering homogenising device HD EnergyIQ is the most efficient homogenising device on the market for high capacities. It achieves the same product quality at lower pressure than conventional homogenising devices, which means reduced costs and environmental impact.
Tetra Alsafe – An aseptic storage tanks that ensures product quality and enables line flexibility – with 24/7 supply to filling lines, flexibility to change the fat content on short notice without stopping production, ability to run milk with different fat contents at the same time, run CIP on the steriliser while production continues on the filling machines and run CIP on a filling line independently of other lines.
Tetra FlexDos – A unit with unique technology for inline aseptic dosing, which enables dairies to produce high value milk products with added ingredients.
Tetra Alcip – A smart CIP unit, for fast, safe and highly efficient inline cleaning. It incorporates intelligent new functions that reduce water consumption, increases the accuracy of detergent concentration and ensures safe, reliable results. It also cuts downtime and bottlenecks while maximising cost-efficiency, and cuts water consumption by up to 21 per cent and detergent consumption by up to 7 per cent.
Tetra PlantMaster – A plant-wide control system that fully and seamlessly integrates the intelligence in each unit of the line. It covers everything from milk reception and processing to filling, palletising, and distribution – all with maximum efficiency and full traceability.

Source: Tetra Pak